Apparatuses and methods for processing a confined area of a workpiece

ABSTRACT

One example of the present disclosure relates to an apparatus for processing a workpiece along a drilling axis, the apparatus comprising an end effector. The end effector comprises a pressure foot, a clamp linearly movable relative to the pressure foot along the drilling axis, and a flat angle drill linearly movable relative to the pressure foot along the drilling axis.

BACKGROUND

An end effector is a device at the end of a robotic arm, designed tointeract with the environment and/or a workpiece. The exactconfiguration of the end effector may depend on the particularapplication of the robot and/or the particular process be performed onthe workpiece. Generally, the end effector may manipulate the workpieceand/or position one or more machining tools relative to the workpieceand/or a surface to be processed.

However, the configuration of the end effector utilized to manipulateand/or process the workpiece may make accessing a processing location,particularly one located in a confined area or near an obstruction,difficult or even impossible. Accordingly, certain operations mayrequire manual processing, for example, utilizing hand tools. Manualprocessing of the workpiece may increase cost and process cycle time ofthe workpiece.

SUMMARY

Accordingly, apparatuses and methods, intended to address theabove-identified concerns, would find utility.

The following is a non-exclusive list of examples of the subject matteraccording the present disclosure, which may or may not be claimed.

One example of the present disclosure relates to an apparatus forprocessing a workpiece along a drilling axis. The apparatus comprises anend effector. The end effector comprises a pressure foot, a clamplinearly movable relative to the pressure foot along the drilling axis,and a flat angle drill linearly movable relative to the pressure footalong the drilling axis.

Another example of the present disclosure relates to a drill bracket forcoupling a flat angle drill to a spindle of an end effector. The flatangle drill comprises a housing, a hexagonal retainer connected to thehousing, and a drilling axis passing through the housing. The drillbracket comprises a drill brace capable of generating a reaction forceF2 equal and opposite to an action force F1 transmittable to the flatangle drill along the drilling axis during a drilling operation, and asplit clamp capable of preventing rotation of the housing of the flatangle drill relative to the drill brace.

Yet another example of the present disclosure relates to a method forprocessing a drilling location in a confined area of a workpiece along adrilling axis using an end effector. The method comprises positioningthe end effector relative to the drilling location of the workpiece,clamping the workpiece between a clamp of the end effector and apressure foot of the end effector, wherein the pressure foot supportsthe clamp movable relative to the pressure foot, and drilling theworkpiece with a flat angle drill of the end effector.

BRIEF DESCRIPTION OF THE DRAWINGS

Having thus described examples of the present disclosure in generalterms, reference will now be made to the accompanying drawings, whichare not necessarily drawn to scale, and wherein like referencecharacters designate the same or similar parts throughout the severalviews, and wherein:

FIG. 1 (FIGS. 1A and 1B) is a block diagram of an apparatus forprocessing a confined area of a workpiece;

FIG. 2 is a schematic perspective view of the apparatus and theworkpiece of FIG. 1, according to one or more examples of the presentdisclosure;

FIG. 3 is a schematic side elevational view of an end effector of theapparatus of FIG. 1, according to one or more examples of the presentdisclosure;

FIG. 4 is a schematic exploded side elevational view of the end effectorof FIG. 3, according to one or more examples of the present disclosure;

FIG. 5 is a schematic illustration of an end effector of the apparatusof FIG. 1, according to one or more examples of the present disclosure;

FIG. 6 is a schematic perspective view of a drill bracket of theapparatus of FIG. 1, according to one or more examples of the presentdisclosure;

FIG. 7 is a schematic exploded perspective view of the drill bracket ofFIG. 6, according to one or more examples of the present disclosure;

FIG. 8 is schematic exploded perspective view of a pressure foot of theapparatus of FIG. 1, according to one or more examples of the presentdisclosure;

FIG. 9 is a block diagram of a method for processing a confined area ofa workpiece, according to one or more examples of the presentdisclosure;

FIG. 10 is a schematic perspective view of a spindle, a drill bracket,and a flat angle drill of the apparatus of FIG. 1, according to one ormore examples of the present disclosure;

FIG. 11 is a schematic exploded side view of the spindle, the drillbracket, and the flat angle drill of FIG. 10, according to one or moreexamples of the present disclosure;

FIG. 12 is schematic perspective view of a translation platform and aspindle drive mechanism of the apparatus of FIG. 1, according to one ormore examples of the present disclosure;

FIG. 13 is a schematic exploded perspective view of the translationplatform and the spindle drive mechanism of FIG. 12, according to one ormore examples of the present disclosure;

FIG. 14 is schematic perspective view of a base and a counterbalance ofthe apparatus of FIG. 1, according to one or more examples of thepresent disclosure;

FIG. 15 is a schematic exploded perspective view of the base and thecounterbalance of FIG. 14, according to one or more examples of thepresent disclosure;

FIG. 16 is schematic perspective view of a clamp of the apparatus ofFIG. 1, according to one or more examples of the present disclosure;

FIG. 17 is a schematic exploded perspective view of the clamp of FIG.16, according to one or more examples of the present disclosure;

FIG. 18 is a schematic perspective view of a pressure foot, an imagingsensor, and a vacuum-lubricant attachment of the apparatus of FIG. 1,according to one or more examples of the present disclosure;

FIG. 19 is a schematic exploded perspective view of the pressure foot,the imaging sensor, and the vacuum-lubricant attachment of FIG. 18,according to one or more examples of the present disclosure;

FIG. 20 is a schematic illustration of a clocked orientation of a flatangle drill of the apparatus of FIG. 1, according to one or moreexamples of the present disclosure;

FIG. 21 is a block diagram of aircraft production and servicemethodology; and

FIG. 22 is a schematic illustration of an aircraft.

DETAILED DESCRIPTION

In FIG. 1, referred to above, solid lines, if any, connecting variouselements and/or components may represent mechanical, electrical, fluid,optical, electromagnetic and other couplings and/or combinationsthereof. As used herein, “coupled” means associated directly as well asindirectly. For example, a member A may be directly associated with amember B, or may be indirectly associated therewith, e.g., via anothermember C. It will be understood that not all relationships between thevarious disclosed elements are necessarily represented. Accordingly,couplings other than those depicted in the block diagrams may alsoexist. Dashed lines, if any, connecting the various elements and/orcomponents represent couplings similar in function and purpose to thoserepresented by solid lines; however, couplings represented by the dashedlines may either be selectively provided or may relate to alternative oroptional examples of the present disclosure. Likewise, elements and/orcomponents, if any, represented with dashed lines, indicate alternativeor optional examples of the present disclosure. Environmental elements,if any, are represented with dotted lines. Virtual imaginary elementsmay also be shown for clarity. Those skilled in the art will appreciatethat some of the features illustrated in FIG. 1 may be combined invarious ways without the need to include other features described inFIG. 1, other drawing figures, and/or the accompanying disclosure, eventhough such combination or combinations are not explicitly illustratedherein. Similarly, additional features not limited to the examplespresented, may be combined with some or all of the features shown anddescribed herein.

In FIG. 9, referred to above, the blocks may represent operations and/orportions thereof and lines connecting the various blocks do not implyany particular order or dependency of the operations or portionsthereof. FIG. 9 and the accompanying disclosure describing theoperations of the methods set forth herein should not be interpreted asnecessarily determining a sequence in which the operations are to beperformed. Rather, although one illustrative order is indicated, it isto be understood that the sequence of the operations may be modifiedwhen appropriate. Accordingly, certain operations may be performed in adifferent order or simultaneously. Additionally, those skilled in theart will appreciate that not all operations described need be performed.

In the following description, numerous specific details are set forth toprovide a thorough understanding of the disclosed concepts, which may bepracticed without some or all of these particulars. In other instances,details of known devices and/or processes have been omitted to avoidunnecessarily obscuring the disclosure. While some concepts will bedescribed in conjunction with specific examples, it will be understoodthat these examples are not intended to be limiting.

Reference herein to “one example” means that one or more feature,structure, or characteristic described in connection with the example isincluded in at least one implementation. The phrase “one example” invarious places in the specification may or may not be referring to thesame example.

Illustrative, non-exhaustive examples of the subject matter accordingthe present disclosure, which may or may not be claimed, are providedbelow.

Referring e.g., to FIGS. 1-8, the instant paragraph pertains to example1 of the present disclosure. Example 1 relates to apparatus 100 forprocessing workpiece 102 along drilling axis A. Apparatus 100 comprisesend effector 104. End effector 104 comprises pressure foot 106, clamp108 linearly movable relative to pressure foot 106 along drilling axisA, and flat angle drill 110 linearly movable relative to pressure foot106 along drilling axis A.

Drilling axis A is an axis along which a drilling operation is performedon workpiece 102. As one general, non-limiting example, drilling axis Amay be defined by an axis passing through flat angle drill 110 (e.g.,drill bit 196 of flat angle drill 110) and workpiece 102 (e.g., surfaceof workpiece 102). As one specific, non-limiting example, drilling axisA may be defined by an axis passing through a center of drill bit 196 offlat angle drill 110 and normal to surface 198 of workpiece 102.

As used herein, “drilling operation” means any machining or cuttingprocess that uses drill bit 196 to form (e.g., cut and/or enlarge) ahole of circular cross-section in solid materials. As one example, thedrilling operation may include forming a fastening aperture (e.g., hole)in or through surface 198 or workpiece 102.

Those skilled in the art will recognize that apparatus 100 may alsoprocess workpiece 102 along one or more other axes that are differentfrom drilling axis A. As one example, apparatus 100 may processworkpiece 102 along an axis through which a milling operation isperformed, for example, an axis that is substantially perpendicular todrilling axis A.

As used herein, “along drilling axis A” means motion in a directioncoincident with or parallel to drilling axis A. As one example, clamp108 being linearly movable relative to pressure foot 106 along drillingaxis A may mean that clamp 108 is linearly movable relative to pressurefoot 106 in a direction (or opposing directions) parallel to drillingaxis A. As one example, flat angle drill 110 being linearly movablerelative to pressure foot 106 along drilling axis A may mean that flatangle drill 110 is linearly movable relative to pressure foot 106 in adirection parallel to drilling axis A.

Referring generally to FIG. 1 and particularly to e.g. FIG. 2, workpiece102 includes any object or article that is processed by apparatus 100.As one example, workpiece 102 may include a raw or partially finishedcomponent or part of an article of manufacture, such as a vehicle (e.g.,an aircraft).

Referring generally to FIG. 1 and particularly to e.g. FIGS. 2 and 5,workpiece 102 may include one or more surfaces 198 to be processed byapparatus 100. Surface 198 may include drilling location 148. Drillinglocation 148 may include a point of contact between surface 198 anddrill bit 196 (e.g., location of the hole to be formed in surface 198).Drilling location 148 may be located in confined area 154 of workpiece102. Confined area 154 may be defined by surface 198 and one or moreobstructions 150. Obstruction 150 may include another surface, feature,and/or structure of workpiece 102 proximate (e.g., at or near) drillinglocation 148. As one example, obstruction 150 may include a flangeextending (e.g., perpendicularly) from surface 198 proximate drillinglocation 148 or extending toward drilling location 148. As one example,obstruction 150 may include another surface of workpiece 102 spaced awayfrom and located over, below, or beside drilling location 148. As oneexample, obstruction 150 may include surface textures (e.g., reinforcingribs) disposed on surface 200 of workpiece 102 opposite drillinglocation 148 (e.g., being opposite of surface 198 upon which drillinglocation 148 is located).

Referring generally to FIG. 1 and particularly to e.g. FIGS. 2 and 5,end effector 104 may be configured to position workpiece 102 betweenpressure foot 106 and clamp 108 prior to the drilling operation. Endeffector 104 may be configured to clamp workpiece 102 between pressurefoot 106 and clamp 108, for example, avoiding obstruction 150, during aclamping operation. End effector 104 with flat angle drill 110 isconfigured to avoid obstruction 150 when being positioned relative todrilling location 148 (e.g., by aligning drilling axis A of flat angledrill 110 with drilling location 148) for performing a drillingoperation on workpiece 102 (e.g., surface 198 of workpiece 102).

As used herein, “clamping operation” means applying a clamping force(e.g., a preload force) to workpiece 102. As one example, and as bestillustrated in FIG. 5, the clamping operation may include contactingsurface 200 of workpiece 102 with clamp 108 and applying (e.g.,exerting) action force F₃ upon workpiece 102 by clamp 108 and contactingsurface 198 of workpiece 102 with pressure foot 106 and applying (e.g.,exerting) reaction force F₄ upon workpiece 102 by pressure foot 106.Reaction force F₄ being equal and opposite to action force F₃.

Referring generally to FIG. 1 and particularly to e.g. FIGS. 3-7 and 11,flat angle drill 110 may be capable of accessing drilling location 148within confined area 154 when positioned, by end effector 104, withrespect to drilling location 148. Flat angle drill 110 may also be knownas a “porkchop”. In one example construction, flat angle drill 110 mayinclude housing 126, hexagonal retainer 146, drive shank 206, and drillbit receiver 212. Housing 126 may include internal transmission (notshown) capable of translating rotational motion of drive shank 206 torotational motion of drill bit receiver 212 and, thus, rotation of drillbit 196. Housing 126 may space drill bit receiver 212 away from driveshank 206 (e.g., drill bit 198 may be offset relative to drive shank 206and spindle 118). Hexagonal retainer 146 may be rigidly connected tohousing 126. Drive shank 206 may be operatively coupled to housing 126(e.g., to internal transmission). Drive shank 206 may extend through andbe freely rotatable relative to (e.g., within) hexagonal retainer 146.Drill bit receiver 212 may be operatively coupled to housing 126 (e.g.,to internal transmission) and capable of receiving drill bit 196 andsecuring drill bit 196 to housing 126. As one example, drill bit 198 maybe threadingly connected to drill bit receiver 212. For example, drillbit receiver 212 may include internal threading and drill bit 196 mayinclude external threading. The threading of drill bit 196 and drill bitreceiver 212 may oppose a direction of rotation of drill bit 196 duringthe drilling operation (e.g., left-hand threading). As one specific,non-limiting example, flat angle drill 110 may be commercially availablefrom Jiffy Air Tool, 2254 Conestoga Drive, Carson City, Nev. 89706.

Referring generally to FIG. 1 and particularly to e.g. FIGS. 3, 4, 6 and7, the instant paragraph pertains to example 2 of the presentdisclosure. In example 2, which includes the subject matter of example1, end effector 104 further comprises base 116, spindle 118 linearlymovable relative to base 116 along drilling axis A, and drill bracket120 fixed relative to spindle 118 and configured to retain flat angledrill 110 in a clocked orientation relative to drill bracket 120 and tobrace flat angle drill 110 along drilling axis A. Flat angle drill 110is configured to be operatively coupled to spindle 118.

As used herein, “clocked orientation” means a rotational (e.g., angular)position of flat angle drill 110 relative to spindle 118 and drillbracket 120. As one example, spindle 118 may include rotational axis R(FIGS. 4, 11 and 20). The clocked orientation of the flat angle drill110 may be the rotational (e.g., angular) position of the flat angledrill 110 about rotational axis R relative to spindle 118 and/or drillbracket 120. As one example, and as best illustrated in FIG. 20, theclocked orientation may be defined by the rotational position ofdrilling axis A (e.g., passing through drill bit 196 and housing 126 offlat angle drill 110) relative to a fixed position of rotational axis R(e.g., passing through drill shank 206 of flat angle drill 110, drillbracket 120 and spindle 118). In the example illustrated in FIG. 20,drilling axis A may have a rotational position of zero degrees relativeto rotational axis R.

Referring generally to FIG. 1 and particularly to e.g. FIGS. 3-5, 10 and11, in one example construction, spindle 118 may include motor (e.g.,motor housing) 208 and drive shaft 210 operably coupled to motor 208.Motor 208 may include any electric motor capable of providing rotationalspeeds of drive shaft 210 suitable for the drilling operation.

Referring generally to FIG. 1 and particularly to e.g. FIGS. 3-7, 10 and11, drive shank 210 of flat angle drill 110 may be operatively coupledto drive shaft 210 of spindle 118. In one example construction, driveshaft 210 may include a drive shank clamp 214 capable of attaching flatangle drill 110 to spindle 118 (e.g., holding and securing drive shank206 to drive shaft 210). As one example, and as illustrated in FIG. 11,drive shank clamp 214 may include a collet and a collet nut capable offorming a collar around drive shank 206 to secure drive shank 206 todrive shaft 210. As one example, drive shank clamp 214 may include achuck to secure drive shank 206 to drive shaft 210.

Drill bracket 120 may engage hexagonal retainer 146 to retain flat angledrill 110 in the clocked orientation relative to drill bracket 120 andprevent rotation of flat angle drill 110 (e.g., housing 126) relative todrill bracket 120. Drill bracket 120 may also engage housing 126 toreact to any torque applied to flat angle drill 110 during the drillingoperation. As one example, and as best illustrated in FIG. 5, drillbracket 120 may generate reaction force F₂ equal and opposite to actionforce F₁ (e.g., torque) transmitted to the flat angle drill 110 (e.g.,housing 126) along the drilling axis A during the drilling operation.

Referring generally to FIG. 1 and particularly to e.g. FIGS. 3-5 and 8,the instant paragraph pertains to example 3 of the present disclosure.In example 3, which includes the subject matter of example 2, endeffector 104 further comprises translation platform 182 linearly movablerelative to base 116 along drilling axis A. Spindle 118 is linearlymovable relative to translation platform 182 along drilling axis A.Pressure foot 106 is fixed relative to translation platform 182.

Referring generally to FIG. 1 and particularly to e.g. FIGS. 3, 4 and12-15, in one example construction, translation platform 182 may beoperably coupled to base 116. As one example, translation platform 182may be movably connected to base 116 such that translation platform 182is linearly movable relative to base 116 along drilling axis A. As oneexample, translation platform 182 may include rail 246 (FIGS. 12 and13). Rail 246 may be connected to rail and carriage bracket 248 of(e.g., connected to) base 116. Rail and carriage bracket 248 (FIG. 15)may be capable of supporting translation platform 182 (e.g., rail 246)and restraining linear motion of translation platform 182 to only alongdrilling axis A relative to base 116.

Referring generally to FIG. 1 and particularly to e.g. FIGS. 3 and 4, inone example construction, spindle 118 may be operatively coupled totranslation platform 182. As one example, spindle 118 may be movablyconnected to transition platform 182 such that spindle 118 is linearlymovable relative to translation platform 182 along drilling axis A.

Referring generally to FIG. 1 and particularly to e.g. FIGS. 3 and 4, inone example construction, drill bracket 120 may be fixedly coupled tospindle 118. As one example, drill bracket 120 may be connected to andsupported by spindle 118 at a fixed position relative to spindle 118.

Referring generally to FIG. 1 and particularly to e.g. FIGS. 3 and 4, inone example construction, pressure foot 106 may be fixedly coupled totranslation platform 182. As one example, pressure foot 106 may beconnected to and supported by translation platform 182 at a fixedposition relative to translation platform 182.

Referring generally to FIG. 1 and particularly to e.g. FIGS. 3 and 4, inone example construction, clamp 108 may be operatively coupled topressure foot 106. As one example, clamp 108 may be movably connected topressure foot 106 such that clamp 108 is linearly movable relative topressure foot 106.

Referring generally to FIG. 1 and particularly to e.g. FIGS. 3, 4, and6, in one example construction, flat angle drill 110 may be fixedlycoupled to drill bracket 120 and operatively coupled to spindle 118. Asone example, flat angle drill 100 may be operatively connected to andsupported by spindle 118 at a fixed position relative to spindle 118 anddrill bracket 120. Flat angle drill 110 may also be connected to andretained by drill bracket 120 at the clocked orientation relative todrill bracket 120.

Thus, linear movement of translation platform 182 relative to base 116may linearly move and position spindle 118, pressure foot 106, drillbracket 120, flat angle drill 110, and clamp 108 along drilling axis A.Linear movement of spindle 118 relative to translation platform 182 maymove and position spindle 118, drill bracket 120, and flat angle drill110 along drilling axis A. Linear movement of clamp 108 relative topressure foot 106 may move and position clamp 108 along drilling axis A.

Referring generally to FIG. 1 and particularly to e.g. FIGS. 3-5, theinstant paragraph pertains to example 4 of the present disclosure. Inexample 4, which includes the subject matter of example 3, end effector104 further comprises spindle drive mechanism 124 to linearly translatespindle 118 relative to translation platform 182 along drilling axis A,and clamp drive mechanism 184 to linearly translate clamp 108 relativeto pressure foot 106 along drilling axis A.

Referring generally to FIG. 1 and particularly to e.g. FIGS. 3, 4, and10-13, spindle drive mechanism 124 may include any linear drivemechanism or linear actuator 222 suitable to or capable of linearlymoving spindle 118 relative to translation platform 182 along drillingaxis A. As one general, non-limiting example, spindle drive mechanism124 (e.g., linear actuator 222) may include a ball-screw drive 222. Asone specific, non-limiting example, spindle drive mechanism 124 mayinclude a ball-screw servo drive linear actuator. Other types of linearactuators are also contemplated without limitation. Spindle drivemechanism 124 may include a sensor 220 (FIG. 13) capable of monitoring alinear position of spindle 118 relative to translation platform 182along drilling axis A.

In one example construction, and as best shown in FIGS. 12 and 13,spindle drive mechanism 124 may be fixedly coupled to translationplatform 182 and operatively coupled to spindle 118. As one example,spindle drive mechanism 124 may be affixed or otherwise mechanicallyconnected to rail 246 of translation platform 182, for example, viafasteners or hardware and operatively connected to spindle 118. In oneexample construction, spindle 118 may include spindle mounting plate 254(FIGS. 10 and 11). Spindle drive mechanism 124 may include spindle drivemechanism mounting plate 256 (FIGS. 12 and 13). Spindle mounting plate254 may be fixedly connected to spindle drive mounting plate 258. As oneexample, spindle mounting plate 254 may have a male projection (e.g., adovetail projection). Spindle drive mechanism mounting plate 256 mayinclude a corresponding female recess or channel (e.g., a dovetailrecess) capable of slidably receiving the male projection of spindlemounting plate 254. Once connected and positioned, spindle mountingplate 254 and spindle drive mechanism mounting plate 256 may be fastenedtogether to fix spindle 118 relative to spindle drive mechanism 124.Spindle drive mechanism mounting plate 256 may be connected to linearactuator 222, such that linear actuator 222 moves spindle drivemechanism mounting plate 256 along drilling axis A relative totranslation platform 182. Linear motion along drilling axis A of spindledrive mechanism mounting plate 256 may be transferred to linear motionof spindle mounting plate 254 along drilling axis A and, thus, tospindle 118 relative to translation platform 182 (e.g., rail 246).

Referring generally to FIG. 1 and particularly to e.g. FIGS. 3, 4, 16and 17, clamp drive mechanism 184 may include any linear drive mechanismor linear actuator 224 suitable to or capable of linearly moving clamp108 relative to pressure foot 106 along drilling axis A. Clamp drivemechanism 184 may include a length of travel suitable to allow frame 122of clamp 108 to avoid (e.g., clear) obstruction 150. As one general,non-limiting example, clamp drive mechanism 184 (e.g., linear actuator224) may include one or more pneumatic actuators (e.g., cylinders). Inthe example construction illustrated in FIGS. 3, 4, 16, and 17, clampdrive mechanism 184 includes four pneumatic actuators. As one specific,non-limiting example, clamp drive mechanism 184 may include a pluralityof three-position pneumatic actuators, such as those commerciallyavailable from Bimba Manufacturing, 25150 S. Governors Hwy, UniversityPark, Ill. 60484. Three-position pneumatic actuators may be advantageousbecause such pneumatic actuators include a center position in additionto an open position and a closed position and two pistons (e.g., insteadof just one piston). Thus, three-position pneumatic actuators mayinclude a maximum (e.g., full) extension and an intermediate stoppingpoint. Clamp drive mechanism 184 may include one or more sensors 234(FIG. 17) capable of monitoring a linear position of clamp 108 (e.g.,frame 122) relative to pressure foot 106 along drilling axis A. As aspecific, non-limiting example, sensors 234 may include magnetic reedswitch sensors.

Referring generally to FIG. 1 and particularly to e.g. FIGS. 3, 4,16-19, in one example construction, frame 122 may be connected to clampdrive mechanism 184. As one example, clamp 108 may include an actuatormounting bracket 226 to connect frame 122 to linear actuators 224. Inone example construction, clamp 108 may include connected to pressurefoot 106. As one example, clamp 108 may include clamp mounting bracket232. Clamp drive mechanism 184 (e.g., linear actuators 224) may beconnected to clamp mounting bracket 232. Clamp mounting bracket 232 maybe connected to pressure foot 106, as best illustrated in FIG. 19. Inone example construction, clamp 108 may include rail and carriagebracket 228 capable of supporting clamp 108 and restraining linearmotion of clamp 108 to only along drilling axis A relative to pressurefoot 106. As one example, frame 122 may be connected to rail andcarriage bracket 228 and rail and carriage bracket 228 may be connectedto clamp mounting plate 232 (e.g., to pressure foot 106) to supportlinear motion of frame 122 relative to pressure foot 106 along drillingaxis A when moved along drilling axis A by clamp drive mechanism 184(e.g., linear actuators 224).

Referring generally to FIG. 1 and particularly to e.g. FIGS. 3-5, theinstant paragraph pertains to example 5 of the present disclosure. Inexample 5, which includes the subject matter of any of examples 3-4, endeffector 104 further comprises counterbalance 176 capable of biasingpressure foot 106 with force F₅ along drilling axis A. Force F₅ isdirectionally opposite to a gravitational force corresponding to aweight sum of spindle 118, translation platform 182, pressure foot 106,drill bracket 120, flat angle drill 110, and clamp 108.

Referring generally to FIG. 1 and particularly to e.g. FIGS. 3-5, 14 and15, in one example, counterbalance 176 may operatively coupletranslation platform 182 to base 116 to provide and/or control linearmovement of translation platform 182 (e.g., and also spindle 118,pressure foot 106, drill bracket 120, flat angle drill 110, and clamp108) relative to base 116 along drilling axis A. Counterbalance 176 maybias spindle 118, translation platform 182, pressure foot 106, drillbracket 120, flat angle drill 110, and clamp 108 against thegravitational force exerted on spindle 118, translation platform 182,pressure foot 106, drill bracket 120, flat angle drill 110, and clamp108 in order to maintain a linear position of spindle 118, translationplatform 182, pressure foot 106, drill bracket 120, flat angle drill110, and clamp 108 relative to base 116 along drilling axis A until theclamping operation is performed. As one general, non-limiting example,counterbalance 176 may include one or more pneumatic cylinders 250 (FIG.15) capable of exerting force F₅ (e.g., a biasing or spring force) uponspindle 118, translation platform 182, pressure foot 106, drill bracket120, flat angle drill 110, and clamp 108.

Referring generally to FIG. 1 and particularly to e.g. FIGS. 3-5 and12-14, in one example construction, counterbalance 176 may beinterconnected between base 116 and translation platform 182. As oneexample, pneumatic cylinders 250 may be fixedly connected to base frame252 of base 116 and operatively connected to rail 246 of translationplatform 182.

As one example implementation of a positioning operation for processingworkpiece 102, clamp 108 may be linearly moved away from pressure foot106 (e.g., relative to pressure foot 106) along drilling axis A (e.g.,to open clamp 108). For example, frame 122 may be linearly moved awayfrom pressure foot 106 (e.g., relative to pressure foot 106) alongdrilling axis A by clamp drive mechanism 184 to open clamp 108. Clamp108 (e.g., frame 122) may be moved a sufficient distance from pressurefoot 106 such that workpiece 102 may be positioned between clamp 108 andpressure foot 106, for example, in preparation for the clampingoperation. End effector 104 may be positioned relative to workpiece 102(e.g., adjacent to workpiece 102). For example, workpiece 102 may bepositioned between pressure foot 106 and clamp 108 and drilling axis Aof flat angle drill 110 (e.g., drill bit 198) may be aligned withdrilling location 148.

In one example implementation of the clamping operation, clamp 108 maybe linearly moved toward pressure foot 106 (e.g., relative to pressurefoot 106) and workpiece 102 along drilling axis A (e.g., to close clamp108). For example, frame 122 may be linearly moved toward pressure foot106 and workpiece 102 along drilling axis A by clamp drive mechanism 184to close clamp 108 and contact surface 202 by jaw 166. When clamp 108contacts workpiece 102, clamp 108 may draw end effector 104 towardworkpiece 102 to contact workpiece 102 by pressure foot 106. Forexample, when jaw 166 of frame 122 contacts surface 202 of workpiece102, clamp drive mechanism 184 may act upon pressure foot 106 tolinearly move pressure foot 106, spindle 118, drill bracket 120, flatangle drill 110, and translation platform 182 relative to base 116 alongdrilling axis A to contact surface 198 of workpiece 102 with pressurefoot 106. A robot control algorithm may be utilized to monitor a gravitymultiplier (e.g., a gravitational force vector) to control force F₅exerted by counterbalance 176 and ensure that end effector 104 (e.g.,pressure foot 106, spindle 118, drill bracket 120, flat angle drill 110,and translation platform 182) moves linearly in a controlled mannerrelative to base 116 along drilling axis A in response to force F₆exerted on workpiece 102 by clamp 108 (e.g., force exerted by clampdrive mechanism 184 on pressure foot 106 to draw pressure foot 106,spindle 118, drill bracket 120, flat angle drill 110, and translationplatform 182 toward workpiece 102). Thus, the clamping operation exertsa suitable clamping force on workpiece 102 between clamp 108 andpressure foot 106 without damaging (e.g., deforming or gauging)workpiece 102 with clamp 108 or pressure foot 106.

Referring generally to FIG. 1 and particularly to e.g. FIGS. 3-5, theinstant paragraph pertains to example 6 of the present disclosure. Inexample 6, which includes the subject matter of example 5, end effector104 is capable of biasing clamp 108 toward workpiece 102 with force F₆.Force F₆ has magnitude M₆ greater than an absolute value of a differencebetween magnitude M₅ of force F₅ and magnitude M_(g) of thegravitational force corresponding to the weight sum of spindle 118,translation platform 182, pressure foot 106, drill bracket 120, flatangle drill 110, and clamp 108.

As one example, force F₆ may be generated by clamp drive mechanism 184.As described herein above, clamp drive mechanism 184 may exert force F₆on workpiece to draw end effector 104 (e.g., pressure foot 106, spindle118, drill bracket 120, flat angle drill 110, and translation platform182) toward workpiece 102 during the clamping operation.

In one example implementation of processing workpiece 102, force F₆ maybe directed in an opposing direction from force F₅. For example, whenend effector 104 is in a right-side up orientation, force F₅ may opposethe gravitational force corresponding to a weight sum of spindle 118,translation platform 182, pressure foot 106, drill bracket 120, flatangle drill 110, and clamp 108 and be directed away from workpiece 102.Force F₆ may be directed toward workpiece 102 and in the oppositedirection from force F5 to draw spindle 118, translation platform 182,pressure foot 106, drill bracket 120, and flat angle drill 110 relativeto base 116 along drilling axis A toward workpiece 102.

As used herein, “right-side up orientation” means an orientation of endeffector 104 in which spindle 118, translation platform 182, pressurefoot 106, drill bracket 120, and flat angle drill 110 are positionedvertically above clamp 108, as best illustrated in FIGS. 2 and 3.

In one example implementation of processing workpiece 102, force F₆ maybe directed in the same direction as force F₅. For example, when endeffector 104 is in an upside down orientation, force F₅ may oppose thegravitational force corresponding to a weight sum of spindle 118,translation platform 182, pressure foot 106, drill bracket 120, flatangle drill 110, and clamp 108 and be directed toward workpiece 102.Force F₆ may be directed toward workpiece 102 and in the same directionas force F5 to draw spindle 118, translation platform 182, pressure foot106, drill bracket 120, and flat angle drill 110 relative to base 116along drilling axis A toward workpiece 102.

As used herein, “upside down orientation” means an orientation of endeffector 104 in which spindle 118, translation platform 182, pressurefoot 106, drill bracket 120, and flat angle drill 110 are positionedvertically below clamp 108 (e.g., rotated 180 degrees from theright-side up orientation).

Referring generally to FIG. 1 and particularly to e.g. FIG. 5, theinstant paragraph pertains to example 7 of the present disclosure. Inexample 7, which includes the subject matter of example 6, magnitude M₅is greater than magnitude M_(g).

For example, magnitude M₅ of force F₅ may be greater than magnitudeM_(g) of the gravitational force corresponding to the weight sum ofspindle 118, translation platform 182, pressure foot 106, drill bracket120, flat angle drill 110, and clamp 108 when end effector 104 is in theright-side up orientation in order to adequately bias spindle 118,translation platform 182, pressure foot 106, drill bracket 120, flatangle drill 110, and clamp 108 away from workpiece 102 and maintainspindle 118, translation platform 182, pressure foot 106, drill bracket120, flat angle drill 110, and clamp 108 at a linear position relativeto base 116 along drilling axis A. Magnitude M₆ of force F₆ may besufficient to overcome magnitude M₅ of force F₅ to draw spindle 118,translation platform 182, pressure foot 106, drill bracket 120, and flatangle drill 110 toward workpiece 102 during the clamping operation.

Referring generally to FIG. 1 and particularly to e.g. FIG. 5, theinstant paragraph pertains to example 8 of the present disclosure. Inexample 8, which includes the subject matter of example 6, magnitude M₅is less than magnitude M_(g).

For example, magnitude M₅ of force F₅ may be less than magnitude M_(g)of the gravitational force corresponding to the weight sum of spindle118, translation platform 182, pressure foot 106, drill bracket 120,flat angle drill 110, and clamp 108 when end effector 104 is in theupside down orientation in order to assist clamp 108 to draw spindle118, translation platform 182, pressure foot 106, drill bracket 120,flat angle drill 110, and clamp 108 toward workpiece 102 relative tobase 116 along drilling axis A. A combination of magnitude M₆ of forceF₆ and magnitude M₅ of force F₅ may be sufficient to overcome magnitudeM_(g) of the gravitational force corresponding to the weight sum ofspindle 118, translation platform 182, pressure foot 106, drill bracket120, flat angle drill 110, and clamp 108 to draw spindle 118,translation platform 182, pressure foot 106, drill bracket 120, and flatangle drill 110 toward workpiece 102 during the clamping operation.

Referring generally to FIG. 1 and particularly to e.g. FIGS. 3 and 5-7,the instant paragraph pertains to example 9 of the present disclosure.In example 9, which includes the subject matter of any of examples 2-8,flat angle drill 110 comprises housing 126. Drilling axis A passesthrough housing 126. Drill bracket 120 comprises drill brace 128 incontact with housing 126 of flat angle drill 110. Drill brace 128produces reaction force F₂ equal and opposite to action force F₁transmitted to housing 126 of flat angle drill 110 along drilling axis Aduring drilling operation.

Referring generally to FIG. 1 and particularly to e.g. FIGS. 5-7 and 11,in one example construction, housing 126 may include housing surface 258and drill brace 128 may include drill brace surface 260. When flat angledrill 110 is coupled to spindle 118 and retained, for example, in theclocked orientation, by drill bracket 120, drill brace surface 260 maybe in contact with and engage housing surface 258. Drill brace surface260 may produce reaction force F₂ through contact with housing surface258. Reaction force F₂ being equal and opposite to action force F₁transmitted to housing 126 of flat angle drill 110 along drilling axis Aduring drilling operation. Drill brace surface 260 may be complimentaryto housing surface 260. As one example, both housing surface 258 anddrill brace surface 260 may be flat. As one example, housing surface 258may include an outward projection or may be outwardly curved (e.g.,convex) and drill brace surface 260 may include a complimentary inwardrecess or may be inwardly curved (e.g., concave).

Referring generally to FIG. 1 and particularly to e.g. FIGS. 3, 4, 6,and 7, the instant paragraph pertains to example 10 of the presentdisclosure. In example 10, which includes the subject matter of example9, drill bracket 120 further comprises split clamp 130 capable ofpreventing rotation of housing 126 of flat angle drill 110 relative todrill brace 128.

Referring generally to FIG. 1 and particularly to e.g. FIGS. 6, and 7,in one example construction, split clamp 130 may engage hexagonalretainer 146 to retain flat angle drill 110 in the clocked orientationrelative to drill bracket 120 and prevent rotation of flat angle drill110 (e.g., housing 126) relative to drill bracket 120.

Referring generally to FIG. 1 and particularly to e.g. FIGS. 3-5, 7, and8, the instant paragraph pertains to example 11 of the presentdisclosure. In example 11, which includes the subject matter of any ofexamples 1-8, flat angle drill 110 comprises housing 126. Pressure foot106 comprises recess 152 capable of at least partially receiving housing126 of flat angle drill 110. Drilling axis A passes through housing 126and recess 152.

Referring generally to FIG. 1 and particularly to e.g. FIGS. 3-5, 7, and8, in one example construction, recess 152 may include a peripheralshape substantially matching a perimeter edge shape of housing 126.Recess 152 may include a depth substantially equal to a thickness ofhousing 126. Recess 152 may center and/or stabilize flat angle drill 110when housing 126 is received within recess 152. During the drillingoperation, housing 126 may be received within recess 152 as spindle 118and flat angle drill 110 move linearly toward workpiece 102 alongdrilling axis A. Pressure foot 106 may include drill bit aperture 272aligned within recess 152, such that drill bit 196 extends through drillbit aperture 272 when housing is received within recess 152.

In one example construction, pressure foot 106 may include first footmember 262 and second foot member 264. First foot member 262 may definea portion of pressure foot 106 facing flat angle drill 110. Second footmember 264 may define a portion of pressure foot 106 facing and tocontact workpiece 102 during processing of workpiece 102 (e.g., duringthe clamping operation).

In one example construction, first foot member 262 may include pressurefoot mounting frame 266 and flat angle drill receiving member 268.Pressure foot mounting frame 266 may be fixedly connected to translationassembly 182 (e.g., rail 246). Flat angle drill receiving member 268 mayextend substantially perpendicularly from pressure foot mounting frame266. Flat angle drill receiving member 268 may include flat angle drillaperture 270 (e.g., a through aperture) suitably sized to receive flatangle drill 110 (e.g., housing 126). Second foot member 264 may becoupled to first foot member 262, for example, to flat angle drillreceiving member 268. Second foot member 264 may partially enclose flatangle drill aperture 270 when connected to first foot member 262 todefine recess 152. Second foot member 264 may include drill bit aperture272 (e.g., a through aperture). Drill bit aperture 272 may be alignedwith, for example, proximate an end of, flat angle drill aperture 270when second foot member 264 and first foot member 262 are connected suchthat drill bit 196 extends through drill bit aperture 272 when housing126 is received within recess 152.

In one example construction, second foot member 264 may include endmember 276 and cap member 278. Cap member 276 may be connected to endmember 276. Drill bit aperture 272 may be disposed through cap member276.

Referring generally to FIG. 1 and particularly to e.g. FIGS. 3, 4, 8,14, 15, 18 and 19, the instant paragraph pertains to example 12 of thepresent disclosure. In example 12, which includes the subject matter ofany of examples 1-11, apparatus 100 further comprises lubricant source186 and vacuum source 188. Pressure foot 106 is fluidly coupled tolubricant source 186 and vacuum source 188.

Referring generally to FIG. 1 and particularly to e.g. FIGS. 3, 4, 8,14, 15, 18 and 19, in one example construction, vacuum source 188 may beany suitable mechanism or device capable of generating a vacuum airflowto pressure foot 106, for example to drill bit aperture 272. The vacuumairflow may vacuum and remove any waste material created during thedrilling operation. As one example, vacuum source 188 may include avacuum pump. Vacuum source 188 may be located on or connected to, forexample, robot 112 or base 116. Vacuum source 188 may be fluidly coupledto pressure foot 106 via vacuum tube 274.

Referring generally to FIG. 1 and particularly to e.g. FIGS. 3, 4, 8,14, 15, 18 and 19, in one example construction, lubricant source 186 maybe any suitable mechanism or device capable of delivering lubricant(e.g., cutting lubricant) to pressure foot 106, for example, to drillbit aperture 272. The lubricant may lubricate drill bit 196 and drillinglocation 148. As one example, lubricant source 186 may include lubricantpump. Lubricant source 186 may be connected to base 116. Lubricantsource 186 may be fluidly coupled to pressure foot 106 via a lubricanttube 280 (FIG. 19).

Referring generally to FIG. 1 and particularly to e.g. FIGS. 3, 4, 8,14, 15, 18 and 19, in an example construction, vacuum tube 274 andlubricant tube 280 may be connected to vacuum-lubricant attachment 282.Vacuum-lubricant attachment 282 may be connected to pressure foot 106 tofluidly interconnect lubricant source 186 and vacuum source 188 topressure foot 106. The vacuum-lubricant attachment 282 may include bothincorporates vacuum circuit capable of controlling a vacuum airflow anda lubricant circuit capable of controlling a flow of lubricant.

Referring generally to FIG. 1 and particularly to e.g. FIGS. 3, 4, and8, the instant paragraph pertains to example 13 of the presentdisclosure. In example 13, which includes the subject matter of example12, pressure foot 106 further comprises vacuum port 190 in fluidcommunication with vacuum source 188 and lubricant port 192 in fluidcommunication with lubricant source 186.

Referring generally to FIG. 1 and particularly to e.g. FIGS. 3, 4, 8,14, 15, 18 and 19, in one example construction, vacuum port 190 andlubricant port 192 may be in fluid communication with drill bit aperture272 in order to apply vacuum airflow and/or lubricant to drill bit 196positioned within drill bit aperture 272 during the drilling operation.In one example construction, pressure foot 106 may include at least onevacuum channel 282 fluidly interconnected between vacuum source 188 andvacuum port 190. Pressure foot may include at least one lubricantchannel 284 fluidly interconnected between lubricant source 186 andlubricant port 192. As an example, vacuum-lubricant attachment 282 maybe fluidly connected to both vacuum channel 284 and lubricant channel286. Vacuum channel 284 and lubricant channel 286 may extend through(e.g., be machine in) pressure foot 106 from an attachment location ofvacuum-lubricant attachment 282 to vacuum port 190 and lubricant port192, respectively, for example, within drill bit aperture 272. As anexample, vacuum channel 284 and lubricant channel 286 may extend throughpressure foot mounting frame 266 of first foot member 262 and extendthrough end member 276 and cap member 278 of second foot member 264 tovacuum port 190 and lubricant port 192, respectively, for example,within drill bit aperture 272.

Referring generally to FIG. 1 and particularly to e.g. FIGS. 3-5, theinstant paragraph pertains to example 14 of the present disclosure. Inexample 14, which includes the subject matter of any of examples 1-13,clamp 108 comprises frame 122 that is G-shaped.

Referring generally to FIG. 1 and particularly to e.g. FIGS. 2-5, frame122, having the G-shape, may provide (e.g., improved) access toworkpiece 102 being processed by apparatus 100. As one example, anupturned portion of the G-shape of frame 122 may allow clamp 108 tocontact workpiece 102 (e.g., surface 200) avoiding obstruction 150.

Referring generally to FIG. 1 and particularly to e.g. FIGS. 3-5, theinstant paragraph pertains to example 15 of the present disclosure. Inexample 15, which includes the subject matter of example 14, frame 122comprises base member 168 comprising first end 162 and second end 164,first arm member 170 extending substantially perpendicularly from firstend 162 of base member 168, second arm member 172 extendingsubstantially perpendicularly from second end of base member 168,extension member 174 extending substantially perpendicularly from secondarm member 172 and substantially parallel to base member 168, and jaw166 at an end of extension member 174. Jaw 166 is aligned with pressurefoot 106 and faces flat angle drill 110.

Referring generally to FIG. 1 and particularly to e.g. FIGS. 2-5, as oneexample, jaw 166 may contact workpiece 102 (e.g., surface 200 ofworkpiece 102) during the clamping operation. In one exampleconstruction, terminal end 202 of jaw 166 may include a tip (e.g.,terminate at a point). Obstruction 150 (e.g., proximate drillinglocation 148) may be avoided during the clamping operation (e.g.,contact with surface 200 by jaw 166) by second arm member 172 of frame122 being spaced away from obstruction 150 and/or surface 200 byextension member 174. As one example, and as best illustrated in FIG. 5,obstruction 150 may include a flange extending from surface 200. Frame122 may clear obstruction 150 such that jaw 166 may contact workpiece102 (e.g., surface 200). As one example, obstruction 150 may include aplurality of spaced apart reinforcing ribs disposed on surface 200. Tip202 of jaw 166 may clear obstruction 150 (e.g., fit between adjacentreinforcing ribs) such that jaw 166 may contact workpiece 102 (e.g.,surface 200).

Referring generally to FIG. 1 and particularly to e.g. FIGS. 2-4, theinstant paragraph pertains to example 16 of the present disclosure. Inexample 16, which includes the subject matter of any of examples 1-15,apparatus 100 further comprises robot 112 and tool changer 114 coupledto robot 112. End effector 104 is coupled to tool changer 114.

Referring generally to FIG. 1 and particularly to e.g. FIG. 2, robot 112may include any multipurpose manipulator of end effector 104 that isautomatically controlled, programmable in three or more axes, andreprogrammable to position end effector 104 relative to workpiece 102during the drilling operation.

Referring generally to FIG. 1 and particularly to e.g. FIG. 2-4, toolchanger 114 may include any suitable robotic tool changer capable ofcoupling end effector 104 to robot 112 and changing from one endeffector to another end effector or other peripheral tooling. As oneexample, end effector 104 may be mechanically connected to tool changer114, electrically connected to tool changer 114, hydraulically connectedto tool changer 114, pneumatically connected and/or vacuum connected totool changer 114. In one example construction, base 116 may be coupledto tool changer 114. As one example, and as best illustrated in FIG. 4,tool changer 114 may include tool changer coupling 216 including one ormore fittings (e.g., mechanical, electrical, hydraulic, pneumatic,and/or vacuum fittings and/or circuits) and base 116 may include basecoupling 218 including one or more corresponding fittings capable ofconnecting base 116 to tool changer 114. End effector 104 may berotationally movable relative to tool changer 114. As one example, base116 may be rotatably connected to or rotationally movable to a pluralityof rotational positions relative to tool changer 114. A lockingmechanism (not shown), for example, a dowel pin, may be used to retainend effector 104 (e.g., base 116) at a desired rotational orientationrelative to tool changer 114. As one specific, non-limiting example,tool changer 114 may include a robotic quick-change tool changerassembly commercially available from ATI Industrial Automation, 1031Goodworth Dr., Apex, N.C. 27539.

Referring e.g., to FIGS. 1 and 3-7, the instant paragraph pertains toexample 17 of the present disclosure. Example 17 relates to drillbracket 120 for coupling flat angle drill 110 to spindle 118 of endeffector 104. Flat angle drill 110 comprises housing 126, hexagonalretainer 146 connected to housing 126, and drilling axis A passingthrough housing 126. Drill bracket 120 comprises drill brace 128 capableof generating reaction force F₂ equal and opposite to action force F₁transmittable to flat angle drill 110 along drilling axis A during adrilling operation, and split clamp 130 capable of preventing rotationof housing 126 of flat angle drill 110 relative to drill brace 128.

Referring generally to FIG. 1 and particularly to e.g. FIGS. 3, 4, 6,and 7, the instant paragraph pertains to example 18 of the presentdisclosure. In example 18, which includes the subject matter of example17, split clamp 130 comprises first bracket member 132 comprising firstarcuate clamping surface 134, second bracket member 136 comprisingsecond arcuate clamping surface 138, and bushing 140 comprisingcylindrical outer surface 142 and hexagonal inner surface 144 capable ofreceiving hexagonal retainer 146 connected to housing 126 of flat angledrill 110. First bracket member 132 and second bracket member 136 arecapable of rotationally constraining cylindrical outer surface 142 ofbushing 140 between first arcuate clamping surface 134 and secondarcuate clamping surface 138.

Referring generally to FIG. 1 and particularly to e.g. FIGS. 3, 4, 6, 7and 20, in one example construction, first bracket member 132 may beconnected to second bracket member 136 to align first arcuate clampingsurface 134 and second arcuate clamping surface 138 to form annularaperture (not visible in FIGS.). Bushing 140 may receive hexagonalretainer 146 and be positioned within annular aperture (e.g., withinopposed first arcuate clamping surface 134 and second arcuate clampingsurface 138). First bracket member 132 and second bracket member 136 maybe tightened together to compress (e.g., frictionally retain) bushing140 (e.g., cylindrical outer surface 142) between first arcuate clampingsurface 134 and second arcuate clamping surface 138 at the clockedorientation.

During the drilling operation, drilling axis A may be required to belocated at and maintained at a suitable (e.g., known and repeatable)rotational (e.g., angular) position (e.g., clocked orientation) relativeto end effector 104 (e.g., rotational axis A), such that drill bit 196may be located at and maintained at the suitable rotational positionrelative to rotational axis A. Thus, flat angle drill 110 may need to berotationally positioned (e.g., clocked) at a particular rotationalposition relative to drill bracket 120 and spindle 118 such thatdrilling axis A is at the suitable location relative to end effector104. However, in certain constructions (e.g., commercially availableconstructions), hexagonal retainer 146 may be affixed (e.g., soldered)to housing 126 at various inconsistent rotational orientations relativeto housing 126. As one example, the rotational orientation of hexagonalretainer 146 relative to housing 126 may vary as much as +/−six degrees.Connection of housing 126 to bushing 140 (e.g., by receiving hexagonalretainer 146 of housing 126 within hexagonal inner surface 144 ofbushing 140) may allow infinite rotational (e.g., angular) positioning(e.g., clocking) of flat angle drill 110 (e.g., housing 126) relative todrill bracket 120 and spindle 118 prior to retaining bushing 140 withinsplit clamp 130 (e.g., between first arcuate clamping surface 134 andsecond arcuate clamping surface 138) at the suitable rotational position(e.g., clocked orientation).

Referring generally to FIG. 1 and particularly to e.g. FIGS. 3, 4, 6, 7,10 and 11, in one example construction, drill bracket 120 may be fixedlyconnected to spindle 118. Thus, linear motion of spindle 118 relative totranslation platform 182 (e.g., vie spindle drive mechanism 124) alongdrilling axis A may translate to linear motion of drill bracket 120 andflat angle drill 110 relative to translation platform 182 along drillingaxis A.

As one example, drill bracket 120 may include third bracket member 288.Third bracket member 288 may be connected to first bracket member 132and second bracket member 136. Third bracket member 288 may be connectedto spindle 118. As one example, third bracket member 288 may be fixedlyconnected to spindle mounting plate 254.

Referring generally to FIG. 1 and particularly to e.g. FIGS. 5-7, theinstant paragraph pertains to example 19 of the present disclosure. Inexample 19, which includes the subject matter of example 17, drill brace128 is in contact with housing 126 of flat angle drill 110.

Referring generally to FIG. 1 and particularly to e.g. FIGS. 3, 4, 6, 7,10 and 11, in one example construction, drill brace 128 may be connectedto first bracket member 132 and second bracket member 136. As oneexample, drill brace 128 may be located directly over housing 126 offlat angle drill 110 with drill brace surface 260 being in contact withhousing surface 258 to generate reaction force F₂ equal and opposite toaction force F₁ transmitted to flat angle drill 110 along drilling axisA during the drilling operation.

Referring generally to FIG. 1 and particularly to e.g. FIGS. 4, 18 and19, the instant paragraph pertains to an example of the presentdisclosure, which includes the subject matter of any of examples 1-19.In an example construction, apparatus 100 may include imaging sensor290. Imaging sensor 290 may be fixedly connected to pressure foot 106and may move linearly relative to translation platform 182 alongdrilling axis A (e.g., with pressure foot 106). Imaging sensor 290 mayinclude any imaging system or device suitable to located and/or monitorworkpiece 102, surface 198, and/or drilling location 148. As oneexample, imaging sensor 290 may include camera 292 and/or laserpositioning (e.g., alignment) sensor 294.

Referring generally to FIGS. 1-8 and 10-19, end effector 104 may includea variety of connecting fasteners, mounting brackets, and/or similarhardware for connecting spindle 118, translation platform 182, pressurefoot 106, drill bracket 120, flat angle drill 110, clamp 108, base 116,spindle drive mechanism 124, and clamp drive mechanism 184 to oneanother and/or together. Such fasteners, brackets, and/or hardware maybe illustrated in drawings and not specifically identified in thepresent description. Such fasteners, brackets, and/or hardware may notbe specifically identified in the present disclosure and/or accompanyingdrawings.

Those skilled in the art will recognize that the examples of the spindle118, translation platform 182, pressure foot 106, drill bracket 120,flat angle drill 110, clamp 108, base 116, spindle drive mechanism 124,and clamp drive mechanism 184 may include more components, lesscomponents, and/or different components that those described and/orillustrated without effecting the scope of the present disclosure.

Referring e.g. to FIG. 9, the instant paragraph pertains to example 20of the present disclosure. Example 20 relates to method 500 forprocessing drilling location 148 in confined area 154 of workpiece 102along drilling axis A using end effector 104. Method 500 comprisespositioning end effector 104 relative to drilling location 148 ofworkpiece 102 (block 202) and clamping workpiece 102 between clamp 108of end effector 104 and pressure foot 106 of end effector 104 (block204). Pressure foot 106 supports clamp 108 movable relative to pressurefoot 106. Method 500 further comprises drilling workpiece 102 with flatangle drill 110 of end effector 104 (block 206).

Referring, e.g. to FIG. 9, the instant paragraph pertains to example 21of the present disclosure. In example 21, which includes the subjectmatter of example 20, clamping workpiece 102 between clamp 108 and thepressure foot 106 comprises exerting action force F₃ upon workpiece 102by contacting workpiece 102 with clamp 108 biased toward workpiece 102in a first direction (block 208), and exerting reaction force F₄, equaland opposite to action force F₃, upon workpiece 102 by contactingworkpiece 102 with pressure foot 106 biased toward workpiece 102 in asecond direction opposite to the first direction (block 210).

Referring e.g. to FIG. 9, the instant paragraph pertains to example 22of the present disclosure. In example 22, which includes the subjectmatter of example 21, method 500 further comprises avoiding obstruction150 proximate drilling location 148 with frame 122 of clamp 108 whenexerting action force F₃ upon workpiece 102 by spacing second arm member172 of frame 122 from obstruction 150 using extension member 174 coupledto second arm member 172 (block 212).

Referring generally to FIG. 9, the instant paragraph pertains to example23 of the present disclosure. In example 23, which includes the subjectmatter of any of examples 21-22, clamping workpiece 102 between clamp108 and pressure foot 106 further comprises biasing pressure foot 106,supporting clamp 108, with force F₅ along drilling axis A (block 214).Force F₅ is directionally opposite to a gravitational forcecorresponding to a weight sum of spindle 118 of end effector 104,translation platform 182 of end effector 104, pressure foot 106, drillbracket 120 of end effector 104, flat angle drill 110, and clamp 108.Clamping workpiece 102 between clamp 108 and pressure foot 106 furthercomprises biasing clamp 108 toward workpiece 102 with force F₆ (block216). Force F₆ has magnitude M₆ greater than an absolute value of adifference between magnitude M₅ of force F₅ and magnitude M_(g) of thegravitational force corresponding to the weight sum of spindle 118,translation platform 182, pressure foot 106, drill bracket 120, flatangle drill 110, and clamp 108. The difference between magnitude M₆ andmagnitude M₅ is equal to magnitude M₄ of force F₄.

Referring generally to FIG. 9, the instant paragraph pertains to example24 of the present disclosure. In example 24, which includes the subjectmatter of example 23, magnitude M5 is greater than magnitude Mg.

Referring generally to FIG. 9, the instant paragraph pertains to example25 of the present disclosure. In example 25, which includes the subjectmatter of example 23, magnitude M5 is less than magnitude Mg.

Referring generally to FIG. 9, the instant paragraph pertains to example26 of the present disclosure. In example 26, which includes the subjectmatter of any of examples 20-25, method 500 further comprises accessingconfined area 154 with flat angle drill 110, and aligning drilling axisA of flat angle drill 110 with drilling location 148 (block 218).

Referring generally to FIG. 9, the instant paragraph pertains to example27 of the present disclosure. In example 27, which includes the subjectmatter of any of examples 20-26, method 500 further comprises opposingaction force F₁, transmitted to flat angle drill 110 along drilling axisA during the processing of drilling location 148, with reaction force F₂produced by drill brace 128 of end effector 104. Reaction force F2 isequal and opposite to action force F1 (block 222).

Examples of the present disclosure may be described in the context ofaircraft manufacturing and service method 1100 as shown in FIG. 21 andaircraft 1102 as shown in FIG. 22. During pre-production, illustrativemethod 1100 may include specification and design block 1104 of aircraft1102 and material procurement block 1106. During production, componentand subassembly manufacturing block 1108 and system integration block1110 of aircraft 1102 may take place. Thereafter, aircraft 1102 may gothrough certification and delivery block 1112 to be placed in serviceblock 1114. While in service, aircraft 1102 may be scheduled for routinemaintenance and service block 1116. Routine maintenance and service mayinclude modification, reconfiguration, refurbishment, etc. of one ormore systems of aircraft 1102.

Each of the processes of illustrative method 1100 may be performed orcarried out by a system integrator, a third party, and/or an operatore.g., a customer. For the purposes of this description, a systemintegrator may include, without limitation, any number of aircraftmanufacturers and major-system subcontractors; a third party mayinclude, without limitation, any number of vendors, subcontractors, andsuppliers; and an operator may be an airline, leasing company, militaryentity, service organization, and so on.

As shown in FIG. 22, aircraft 1102 produced by illustrative method 1100may include airframe 1118 with a plurality of high-level systems 1120and interior 1122. Examples of high-level systems 1120 include one ormore of propulsion system 1124, electrical system 1126, hydraulic system1128, and environmental system 1130. Any number of other systems may beincluded. Although an aerospace example is shown, the principlesdisclosed herein may be applied to other industries, such as theautomotive industry. Accordingly, in addition to aircraft 1102, theprinciples disclosed herein may apply to other vehicles, e.g., landvehicles, marine vehicles, space vehicles, etc.

Apparatus and methods shown or described herein may be employed duringany one or more of the stages of the manufacturing and service method1100. For example, components or subassemblies corresponding tocomponent and subassembly manufacturing 1108 may be fabricated ormanufactured in a manner similar to components or subassemblies producedwhile aircraft 1102 is in service. Also, one or more examples of theapparatus, method, or combination thereof may be utilized duringproduction stages 1108 and 1110, for example, by substantiallyexpediting assembly of or reducing the cost of aircraft 1102. Similarly,one or more examples of the apparatus or method realizations, or acombination thereof, may be utilized, for example and withoutlimitation, while aircraft 1102 is in service, e.g., maintenance andservice stage block 1116.

Different examples of the apparatus and methods disclosed herein includea variety of components, features, and functionalities. It should beunderstood that the various examples of the apparatuses and methodsdisclosed herein may include any of the components, features, andfunctionalities of any of the other examples of the apparatuses andmethods disclosed herein in any combination, and all of suchpossibilities are intended to be within the spirit and scope of thepresent disclosure.

Many modifications of examples set forth herein will come to mind to oneskilled in the art to which the present disclosure pertains having thebenefit of the teachings presented in the foregoing descriptions and theassociated drawings.

Therefore, it is to be understood that the present disclosure is not tobe limited to the specific examples presented and that modifications andother examples are intended to be included within the scope of theappended claims. Moreover, although the foregoing description and theassociated drawings describe examples of the present disclosure in thecontext of certain illustrative combinations of elements and/orfunctions, it should be appreciated that different combinations ofelements and/or functions may be provided by alternative implementationswithout departing from the scope of the appended claims.

What is claimed is:
 1. An apparatus (100) for processing a workpiece(102) along a drilling axis (A), the apparatus (100) comprising an endeffector (104), the end effector (104) comprising: a pressure foot(106); a clamp (108) linearly movable relative to the pressure foot(106) along the drilling axis (A); a flat angle drill (110) linearlymovable relative to the pressure foot (106) along the drilling axis (A);a spindle (118); a drill bracket (120); a translation platform (182); acounterbalance (176) capable of biasing the pressure foot (106) with aforce (F₅) along the drilling axis (A), wherein the force (F₅) isdirectionally opposite to a gravitational force corresponding to aweight sum of the spindle (118), the translation platform (182), thepressure foot (106), the drill bracket (120), the flat angle drill(110), and the clamp (108), wherein the end effector (104) is capable ofbiasing the clamp (108) toward the workpiece (102) with a force (F₆) andwherein the force (F₆) has a magnitude (M₆) greater than an absolutevalue of a difference between a magnitude (M₅) of the force (F₅) and amagnitude (M_(g)) of the gravitational force corresponding to the weightsum of the spindle (118), the translation platform (182), the pressurefoot (106), the drill bracket (120), the flat angle drill (110), and theclamp (108).
 2. The apparatus (100) of claim 1, wherein the end effector(104) further comprises a base (116), and wherein the spindle (118) islinearly movable relative to the base (116) along the drilling axis (A).3. The apparatus (100) of claim 2, wherein: the translation platform(182) is linearly movable relative to the base (116) along the drillingaxis (A), and the spindle (118) is linearly movable relative to thetranslation platform (182) along the drilling axis (A).
 4. The apparatus(100) of claim 3, wherein the end effector (104) further comprises: aspindle drive mechanism (124) to linearly translate the spindle (118)relative to the translation platform (182) along the drilling axis (A);and a clamp drive mechanism (184) to linearly translate the clamp (108)relative to the pressure foot (106) along the drilling axis (A).
 5. Theapparatus (100) of claim 2, wherein: the flat angle drill (110)comprises a housing (126), the drilling axis (A) passes through thehousing (126), the drill bracket (120) comprises a drill brace (128) incontact with the housing (126) of the flat angle drill (110), and thedrill brace (128) produces a reaction force (F₂) equal and opposite toan action force (F₁) transmitted to the housing (126) of the flat angledrill (110) along the drilling axis (A) during a drilling operation. 6.The apparatus (100) of claim 5, wherein the drill bracket (120) furthercomprises a split clamp (130) capable of preventing rotation of thehousing (126) of the flat angle drill (110) relative to the drill brace(128).
 7. The apparatus (100) of claim 1, wherein: the flat angle drill(110) comprises a housing (126), the pressure foot (106) comprises arecess (152) capable of at least partially receiving the housing (126)of the flat angle drill (110), and the drilling axis (A) passes throughthe housing (126) and the recess (152).
 8. The apparatus (100) of claim1, further comprising a lubricant source (186) and a vacuum source(188), wherein the pressure foot (106) is fluidly coupled to thelubricant source (186) and the vacuum source (188).
 9. The apparatus(100) of claim 8, wherein the pressure foot (106) further comprises: avacuum port (190) in fluid communication with the vacuum source (188);and a lubricant port (192) in fluid communication with the lubricantsource (186).
 10. The apparatus (100) of claim 1, wherein the clamp(108) comprises a frame (122), the frame (122) comprising: a base member(168) comprising a first end (162) and a second end (164); a first armmember (170) extending substantially perpendicularly from the first end(162) of the base member (168); a second arm member (172) extendingsubstantially perpendicularly from the second end of the base member(168); an extension member (174) extending substantially perpendicularlyfrom the second arm member (172) and substantially parallel to the basemember (168); and a jaw (166) at an end of the extension member (174),wherein the jaw (166) is aligned with the pressure foot (106) and facesthe flat angle drill (110).
 11. The apparatus (100) of claim 1, whereinthe magnitude (M₅) is greater than the magnitude (M_(g) ).
 12. Theapparatus (500) of claim 1, wherein the magnitude (M₅) is less than themagnitude (M_(g) ).
 13. The apparatus (100) of claim 1, wherein theclamp (108) comprises a frame (122).
 14. The apparatus (100) of claim 1,wherein the frame (122) is G-shaped.
 15. The apparatus (100) of claim 1,further comprising a robot (112).
 16. The apparatus (100) of claim 15,further comprising a tool changer (114) coupled to the robot (112). 17.The apparatus (100) of claim 16, wherein the end effector (104) iscoupled to the tool changer (114).
 18. The apparatus (100) of claim 2,wherein the drill bracket (120) is fixed relative to the spindle (118)and is configured to retain the flat angle drill (110) in a clockedorientation relative to the drill bracket (120) and to brace the flatangle drill (110) along the drilling axis (A).
 19. The apparatus (100)of claim 2, wherein the flat angle drill (110) is configured to beoperatively coupled to the spindle (118).
 20. The apparatus (100) ofclaim 3, wherein the pressure foot (106) is fixed relative to thetranslation platform (182).